Time Attack/Circuit Racer Mitsubishi Evo V

[tonioseven]

Okay, you have my attention!!

[Decs0105]

awesome stuff, love it!

[mike@af]

Well, I was finally able to get into the shop and get some work done this weekend. I decided I would start on the front center-lock spindles. I started with a 3/8" diameter chunk of 304 Stainless Steel. I tried several materials, including 7075 Aluminum; 303 Stainless; and 6AL-4V Titanium, before settling on 304SS. I needed something that I could take light passes on (.0025") for threading without galling.


I started roughing out the overall shape of the spindle first. Flooding coolant really helps avoid chatter and a nicer finish.


Threads for the wheel nuts! I was really worried the threads wouldn't turn out very well, but I was quite impressed. I had to grind a carbide tool to a perfect razor sharp point to cut the threads since they are only .0025" (.01mm) deep. The thread pitch is .2mm on a diameter of .080" (2.03mm).


After drilling the holes for the drive pins, I started machining out the slots between the bearing races. These slots serve no real purpose other than cooling the ceramic bearings. But of course, that would be if this were a real car!


US $0.01 Coin for comparison.


This is why this spindle has earned the title of "The 9-Hour Fuck-Up". During the very last operation, closing in on 9 hours of machining and tool grinding, I was drilling out the spindle. The drill caught one of the slots and twisted the spindle and destroyed the slots.

However, I did learn a lot on the way I want to machine the spindles. I did figure out some good techniques for cutting so I am sure the new ones will be better and take a lot less time since I wont have to regrind my custom tools. This just goes to show, two things.

1. I am far from a professional machinist.
2. There are no failures in modeling, only lessons of what not to do!

[Hemi Killer]

ugh...I know how that feels.

pretty awesome even though its broken

I have been wanting to get a lathe. I cant afford one right now, but eventually. I can only imagine the frustration...but I bet you wont do that again

[ZoomZoomMX-5]

Uh, Mike...that part looks perfectly normal for a Mitsubishi

[John18d]

GTmike400 - you are insane with the detail of this build - John - insane in a good way - John

[dozman]

Mike

Very impressive though!

[auw12]

Hi Mike, you work is beyond my English skill, I have to only curse if I may. I'm recently considering about getting myself a lathe, but you're sort of keeping me away from that, those works just seemed impossible for me. Good luck on this build, please, finish it!

[ridefast]

Amazing! Simply amazing.

Originally Posted by GTmike400

1. I am far from a professional machinist.

Yeah, right... Nobody is going to believe that for sure

[modlman17]

Have I missed something? Why are you doing a new chassis?
Rob

[mike@af]

A few weeks ago I finally started designing the cylinder head in my hotel room. I had been putting it off for months because of the tremendous detail and little nuances involved. Since I was out of town (in Clay's ol' childhood town) I figured I'd spend some time designing. After about 40 hours of design, I'd finished the overly complicated and detailed cylinder head.









I wasnt quite sure how I was going to make it after designing it since it was so detailed. One of the great things about my job is having access to 3D printers. I sent the work off to the 3D printer with .1mm resolution, and soon enough I had a few cylinder heads. The prints are translucent, so I shot them with some white primer laying around. I need to get some gray primer since it's pretty hard to see the detail in white.







Thanks for looking!

Originally Posted by auw12

Hi Mike, you work is beyond my English skill, I have to only curse if I may. I'm recently considering about getting myself a lathe, but you're sort of keeping me away from that, those works just seemed impossible for me. Good luck on this build, please, finish it!

Glad I can provide some inspiration! If you have any questions, please ask!

Originally Posted by modlman17

Have I missed something? Why are you doing a new chassis?
Rob

Hi Rob, when I first started this project I had no intentions of completing it. I never designed anything since it was a test to see how difficult it was to build a brass chassis. In short, the suspension wasn't ever going to fit the way I wanted it to since I want to do a pushrod style suspension. Therefore, I'm designing a new chassis in 3D first, before I spend all the time building a new one so I know everything fits!

[Robi J]

Fantastic, the only thing I could say...

Bravo Mike !

R

[gionc]

Mike.... it is fantastic!!!!

I liked the bidykit also, a lot.
Great style, man: perfect balance between race and design.

[924_CarreraGTS]

The cylinder head looks great. What model of 3D printer did you use? I have worked with Dimension in the past.

[geist_casper]

nothing else
daniel